Flat foldable carton having a supported intermediate tray

ABSTRACT

A carton is provided which may be prepared from an integral blank and which when properly glued together, may be stored in flat folded condition. The folded carton may be quickly erected to form a carton in the form of a polygonal prism having a closed bottom and another end which is readily closable by interlocking a plurality of flaps. A separate tray is provided which is inserted into the carton at an intermediate position. The side walls of the carton are suitably cut and scored to provide tabs which, upon erection of the carton, are punched inwardly to provide vertically oriented supports for the tray.

United States Patent [1 1 Randy [451 Oct. 30, 1973 FLAT FOLDABLE CARTON HAVING A SUPPORTED INTERMEDIATE TRAY [76] Inventor: Patrick L. Bundy, Battle Creek,

Mich.

[22] Filed: Nov. 18, 1971 [21] Appl. No.: 199,916

Related US. Application Data [63] continuatiomin-part of Ser. No. 54,997, July 15,

1970, Pat. NO. 3,700,161.

[52] US. C1. 229/15, 229/39 R, 229/41 C,

229/52 AL [51] int. Cl B656 5/36, B65d 5/46 [58] Field of Search 229/39, 41 C, 41 B,

229/52 AL, 52 AW, 15, 42; 217/265; 206/4531; 248/174 [56] References Cited UNITED STATES PATENTS 3,014,637 12/1961 Wilson 229/41 C UX 3,044,105 7/1962 Wigemark 229/52 AL X 3,315,574 4/1967 Field et a1. 229/52 AL X 3,101,167 8/1963 Styler 229/41 C 3,174,675 3/1965 Rosenburg, Jr. 229/41 C 3,700,161 10/1972 Bundy 229/41 C 3,021,046 2/1962 Pullen 229/39 B 3,058,585 10/1962 Budd... 229/39 R X 1,547,903 7/1925 Cole 229/15 2,240,282 4/1941 Beanam 248/174 3,565,326 2/1971 Turkovich 229/42 FOREIGN PATENTS OR APPLICATIONS Primary Examiner-Davis T. Moorhead Att0rneyRoy A. Plant et al.

[57] ABSTRACT A carton is provided which may be prepared from an integral blank and which when properly glued together, may be stored in flat folded condition. The folded carton may be quickly erected to form a carton in the form of a polygonal prism having a closed bottom and another end which is readily closable by interlocking a plurality of flaps.

A separate tray is provided which is inserted into the carton at an intermediate position. The side walls of the carton are suitably cut and scored to provide tabs which, upon erection of the carton, are punched inwardly to provide vertically oriented supports for the tray.

8 Claims, 19 Drawing Figures 5/1939 Great Britain 229/41 C PAIENTEDnm 30 Ian SHEET 1 UP 4 INVENTOR PATRICK L. BUNDY ATTORNEYS PAIENTEDHBI 30 ms 3.768.720 SHEET 2 BF 4 4,39 I/ ,Ma 4 714 ,1/35

.. INVENTOR T165 PATRICK L. BUNDY BY 1 mm ATTORNEYS PAIENIEDucr 30 am 3. 768.720 sum 3 BF 4 INVENTOR PATRICK L.BUNDY WW/ M ATTORNEYS PAIENIEUUBI30 I925 3,768,720 sum u or a INVENTOR PATRIC K L. BUN DY B M uA NW ATTOR NEYS FLAT FOLDABLE CARTON HAVING A SUPPORTED INTERMEDIATE TRAY This application is a continuation-in-part of pending application Ser. No. 54,997, filed July 15, 1970, for A FLAT FOLDABLE CARTON HAVING A PRE- FORMED ANCHORED IN PLACE, AND FOLDED BOTTOM, WITH SELF-LOCKING TOP, by the present inventor, now U.S. Pat. No. 3,700,161, issued Oct. 24, 1972.

BACKGROUND OF THE INVENTION The invention deals broadly with foldable boxes or cartons, and more particularly refers to such cartons which may be erected into polygonal and preferably hexagonal prism form having one closed end and another which is readily closed and locked.

Polygonal and particularly hexagonal cartons have been disclosed in the art, but because of their form, they are generally not able to be folded flat for storage. However, even where collapsible hexagonal cartons have been provided, the strength and rigidity particularly of the bottom end are not sufficient for containing such articles as parts of fried chicken. Such items are generally placed in bucket-type paper cartons which are not foldable, and therefore require a considerable amount of storage space. Additionally, prior art cartons of prismatic form generally have only a single compartment. Consequently, when two different food items are to be packaged together in the carton, as for example fried fish and french-fried potatoes, the excess grease of one food item such as fish may drain onto the other food item such as french-fried potatoes, and thereby render them exceedingly and undesirably soggy.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a carton which can be glued and erected in the shape of a polygonal and preferably hexagonal prismatic form.

It is a primary object of the invention to provide a carton of the type described having an intermediately disposed tray and means for supporting the tray, in order to permit two different items to be separately packaged within the carton.

It is another object of the invention to provide a bottom for the carton which, although it may be folded flat for storage, it can be readily set up to provide a strong, full bottom which additionally aids in retaining the polygonal shape of the carton.

- It is still further an object to provide a carton having such a bottom which will contain even small items without danger of loss.

It is still further an object to provide a hexagonal carton having improved closing and locking means.

It is an additional object to provide a carton of the type described which can be formed of an integral blank suitably cut and scored.

Still further objects and advantages of the invention will appear as the description proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS To the accomplishment of the foregoing and related ends, the invention, then, consists of the carton herein fully described and particularly pointed out in the claims, the annexed drawings and the following description setting forth in detail certain illustrative embodiments of the invention, such disclosed embodiments illustrating, however, but several of the various ways in which the principle of the invention may be used.

In the annexed drawings:

FIG. I is a perspective view of a fully erected and closed carton according to the invention illustrating the top closure.

FIG. 2 is a perspective view of the carton of FIG. 1 illustrating the bottom closure.

FIG. 3 is a plan view of an integral blank which may be utilized to form a carton such as shown in FIGS. 1 and 2.

FIG. 4 is a plan view ofa carton which has been glued together but which is folded flat in storage condition.

FIG. 5 is an end view taken at the line V-V of FIG. 4, looking in the direction of the arrows.

FIG. 6 is a top view of the carton of FIGS. 1-5 which has been glued, the bottom folded in place, and the top flaps open for filling the carton.

FIG. 7 is a top view of the carton of FIG. 6 in which the flaps are in partially closed condition.

FIG. 8 is a top view showing the carton of FIGS. 6 and 7 with the top completely closed and the flaps interlocked.

FIG. 9 is a side elevational view showing the top not completely closed.

FIG. is a fragmentary elevational view showing the top completely closed.

FIG. 11 is a cross-sectional view taken at line XIXI of FIG. 10, looking in the direction of the arrows.

FIG. 12 is a bottom view of the carton of the invention.

FIG. 13 is a sectional view taken at the line XIIIX- III of FIG. 12, looking in the direction of the arrows.

FIG. 14 is a sectional view taken at the line XlV-XIV of FIG. 13, looking in the direction of the arrows.

FIG. 15 is a plan view of a blank for forming a tray.

FIG. 16 is a perspective view of the tray of FIG. 15 with the edges folded and ready for insertion into the carton.

FIG. 17 is a cross-sectional view taken at the line XVII-XVII of FIG. 1, looking in the direction of the arrows.

FIG. I8 is an axial cross-sectional view taken at the line XVIII-XVIII of FIG. 11, looking in the direction of the arrows, illustrating the tray supported by the support tabs; and

FIG. 19 is a plan view of a handle.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS Referring more particularly to FIGS. 1 and 2, the carton I0 is shown in perspective having a top closure 33 and a bottom closure 34. FIG. 3 illustrates an integral blank 11 from which the carton may be constructed and in which the various panels may be more clearly distinguished. The carton comprises side panels 12, 13, 14, I5, 16 and I7, and a glue flap 18 and 18a for affixing the edge of the panel 17 to the edge of the panel 12 by means of an adhesive 19 such as glue applied to the edge of the panel 12 and flap 20. The top closure is comprised of a plurality of top flaps 20, 21, 22, 23, 24 and 25 affixed to the ends of the side panels at hinge lines 26, 27, 28, 29, 30 and 31, respectively. The top flaps are connected together by triangular webs 36, 37, 38, 39, 40 and 41 at hinge lines 42, 43, 44, 45, 46, 47, 48, 49, 50, SI, 52 and 32. Each of the top flaps 20-25 have one lateral edge (35, 13, 45, 4'7, 49 and 51) perpendicular to the respective fold lines 26-31 of the flaps. Additionally, each flap 20-25 has one lateral edge (42, 44, 46, 48, 50 and 52) oblique with respect to the fold lines 26-31 of the flaps. In similar manner, each of the triangular Webs 36-41 has a lateral edge (43, 45, 4'7, 49, S1 and 32) perpendicular to the fold lines 26-31, and another lateral edge (42, 44, -16, 48, 51) and 52) oblique to the fold lines. This arrangement permits the flaps 20-25 to be positioned either coplanar with the lateral panels 12-17 to present an open end of the carton, or alternatively perpendicular to the panels and cooperating with the triangular webs to form the interlocking pattern shown in FIG. 1. Each of the flaps 20-25 are provided at their ends with semicircular tabs 53, 54, 55, 56, S7 and 58.

The bottom closure, FIG. 3, comprises a hexagonal flap 65 having a tab 64 at its end, and a pair of supporting flap assemblies. One supporting flap assembly 66 comprises a supporting flap member 67 and a triangular glue flap member 68 connected thereto at a hinge line 69. An end supporting flap 70 is hingedly connected to the side panel 14. At the other side of the hexagonal flap 65 is another flap assembly 75 comprising a supporting flap member 76 and a triangular glue flap member 77 connected thereto at a hinge line 78. The flap members 67 and 76 are provided with arcuate or rounded edges to prevent entanglement with other flaps or panels. An end supporting flap 79 is hingedly connected to the side panel 16. The end supporting flaps 70 and 79 are provided with recesses 85 and 86, respectively, to provide clearance of the hexagonal flap 65. Ventilation holes 60, 61 and 62 may be provided in the carton top if desired.

In gluing the carton together, the hexagonal flap 65 is first folded over against the side panels 14, and 16. The flap assembly 75 and end supporting flap 79 are then folded over against the side panels 16 and 17. The triangular glue flap member 77 is then folded back against the flap 76 and glue placed on the exposed surface of the triangular glue flap 77. The side panel 17 is then folded over against the side panel 16. The triangular glue flap 77 is thereby adhesively affixed to a medial portion of the end supporting flap 79 but leaving an overhang 79a, FIG. 14, of the flap 79 beyond the glue flap supporting member 77. The flap assembly 66 and end flap 70 are then folded over against the side panels 13 and 14. The triangular glue flap member 68 is then folded back against the flap 67 and glue applied. The panel 13 is then folded over against the panel 14, causing the triangular glue flap member 68 to be adhesively affixed to a medial portion of the end flap 70 but leaving an overhang 70a, P16. 14. Glue 19 is then applied to the edge of the side panel 12 and end panel which are then caused to be affixed to the glue strip 15 and 15a, the carton then being of the form shown in FIGS. 4 and 5, and in which condition the carton may be stored and transported.

According to the invention, a tray 91) is formed from an integral blank suitably cut and scored to provide a main panel 51, and corner flaps 92, 93, 94 and 95 hingedly connected to the main panel 91 at score lines 96, 97, 98 and 99, respectively. Lateral flaps 100 and 1111 are hingedly connected to the main panel 91 by means of score lines 102 and 103. In order to provide a supporting structure for the tray 90, side panels 13, 14, 16 and 17 are suitably cut to provide support tabs 106, 107, 108 and 109 (FIGS. 1-4), which when punched inwardly during assembly of the carton, assume vertically and inwardly oriented positions, serving to support the tray 90, as shown in FIG. 18. In the embodiment shown four tabs are utilized which are symmetrically distributed. This configuration results in a strong supporting means for the tray 90. Additionally, the positioning of each pair of tabs on adjacent side panels permits the tabs to be punched in easily by the thumb and forefinger of each hand when the carton is being set up. Alternatively three tabs or more than four could be utilized. A pair of apertures 112 and 113 are provided for anchoring the ends of a plastic handle 114 having transverse lugs 115 which form an integral part of the handle (FIGS. 1 and 19) which engage the inner surfaces of the carton. The ends of the handle 114 are inserted into the apertures 112 and 113, with the lugs 115 completely within the carton.

The carton is erected by compressing together the opposite side edges, thereby opening the carton, and then pushing the hexagonal flap 65 outwardly until it engages the glued together flaps 67 and 70, and 76 and 79, which flaps retain the hexagonal flap 65 in position. The tab 64 is at the same time bent until its flap surface engages the panel 12, thereby forming a substantially leakproof container, as shown in FIGS. 12, 13 and 14. In this condition the overhanging areas a and 79a reinforce the bottom and prevent outward bending of the flap at the hinge lines 69 and 78 (FIGS. 12, 13 and 14).

The tray is prepared for insertion into the carton by turning up the flaps 92, 93, 94 and and the lateral flaps 101) and 101, as shown in FIG. 16. The contents to be inserted into the lower portion of the carton, as for example fried fish or chicken, are placed therein. The support tabs 106, 107, 108 and 109 are then punched inwardly to provide a support for the tray. The tray 911 is then inserted into the carton with the flaps extended upwardly, and pushed downwardly until it engages the support flaps. The remaining contents, as for example french-fried potatoes, are then placed into the carton above the tray.

After the desired contents have been placed in the carton, the carton is closed by first forming a star pattern such as shown in FIG. '7, and pinching toward the center, as shown in FIGS. 7 and 9. When the flaps reach the flattened position as shown in FIGS. 8, 10 and 11, the flaps are interlocked and the top remains closed. The top may be opened by raising and disengaging the flaps.

The carton of the present invention has many advantages over prior art cartons. The primary advantage is that it permits two different products to be packaged within the carton but maintained in separated state so that there is no intermixing. This is particularly advantageous when a food item such as fried fish or fried chicken is to be packaged together with another food item such as french-fried potatoes. The presence of a tray maintains the two different food items in separated condition, and prevents excess grease from the food items such as fried fish or fried chicken from mixing with the french-fried potatoes, a condition which generally causes the potatoes to become overly soggy. The tray structure is quite simple to assemble and insert, and in cooperation with the easily set-up support tabs, forms a very strong separating structure.

Other features of the carton are additionally advantageous. Because of the arrangement of the bottom flaps which are glued together and which sustain the hexagonal flap, an exceedingly strong supporting bottom structure is formed. The closure structure is further strengthened by the presence of the supporting flap overhangs which prevent the flaps from bowing outward at the glue flap hinge lines. Moreover, the bottom flaps are so arranged that they may be folded for storage. Additionally, because of the unique pattern of the flaps and because of the way in which they fold, the entire carton may be readily folded flat for storage and transportation, and subsequently quickly erected. The unique arrangement of the top flaps provides a positive locking and attractively appearing top.

While but one embodiment of the invention has been illustrated and described herein, it is to be understood that minor modifications may be made to the carton, as well as the construction and arrangement of its bottom flaps within the spirit and scope of the invention, as herein set forth. It is also to be noted that while directional terms have been used, same are not to be construed as a limitation of the invention since such use has been availed of to better describe the invention in the position illustrated in the drawings.

I claim:

1. A carton in the form of a polygonal prism comprising:

a plurality of side panels,

a top closure,

a bottom closure,

. a tray positioned intermediate said top closure and said bottom closure, and

e. support means associated with said side panels engaging and supporting said tray, wherein some of said side panels are appropriately cut and formed to provide a plurality of planar tabs extending inwardly and in a vertical plane with respect to said carton, said tabs engaging and supporting said tray at their edges.

2. A carton according to claim 1, having at least six sides.

3. A carton according to claim 1, which is hexagonal.

4. A carton according to claim 1, wherein said tabs have arcuate ends.

5. A carton according to claim 1, wherein said tray is provided with vertically extending flaps frictionally engaging the side panels of said carton.

6. A carton according to claim 1, wherein said top closure comprises a plurality of closure flaps hingedly connected to the ends of said side panels and interconnected laterally to form a closed loop, each of said closure flaps comprising a flap member and a triangular web hingedly connected thereto, said flap members and said webs each having an edge perpendicular to the hinge line connecting said flap members and said side panels and another edge oblique thereto, the oblique edges of said flap members and said webs being hingedly connected together, and the perpendicular edges of said flap members and triangular webs being connected to the perpendicular edges of webs and flap members, respectively, of adjacent closure flaps, the oblique edges of said flap members passing through the center of said closure when said flap members are in closed condition, said flap members terminating in an arcuate tab extending beyond the center of said closure.

7. A carton according to claim 6, wherein said bottom closure comprises:

a. a polygonal bottom panel being connected at one edge to the end of one of said side panels and having substantially the same dimensions and shape as the cross-section of said carton, and

b. two supporting flap assemblies disposed one on each side of and below said polygonal bottom panel, each of said assemblies comprising:

1. a first supporting flap hingedly connected to the end of one of said side panels,

2. a second supporting flap hingedly connected to the end of an adjacent one of said side panels comprising a supporting flap member and a glue flap member hingedly connected thereto, and

3. said glue flap being adhesively affixed to a medial portion of said first supporting flap and said first supporting flap having an overhanging portion extending beyond the hinge line between said supporting member and said glue member, the arrangement being such that each supporting flap assembly folds inwardly at the hinge line between said hinge member and said flap member permitting said bottom closure to be folded flat with the remainder of said carton for storage, and whereby when said carton is erected and said bottom closure is placed in planar position said overhang abuts the upper surface of said supporting flap member, thereby restraining said flap assembly from bending outwardly of said carton, and providing positive support for said polygonal flap.

8. A carton according to claim 1, wherein a pair of apertures are provided in the side panels, a handle the ends of which pass through said apertures, and means anchoring the ends of said handle within said carton. 

1. A carton in the form of a polygonal prism comprising: a. a plurality of side panels, b. a top closure, c. a bottom closure, d. a tray positioned intermediate said top closure and said bottom closure, and e. support means associated with said side panels engaging and supporting said tray, wherein some of said side panels are appropriately cut and formed to provide a plurality of planar tabs extending inwardly and in a vertical plane with respect to said carton, said tabs engaging and supporting said tray at their edges.
 2. A carton according to claim 1, having at least six sides.
 2. a second supporting flap hingedly connected to the end of an adjacent one of said side panels comprising a supporting flap member and a glue flap member hingedly connected thereto, and
 3. said glue flap being adhesively affixed to a medial portion of said first supporting flap and said first supporting flap having an overhanging portion extending beyond the hinge line between said supporting member and said glue member, the arrangement being such that each supporting flap assembly folds inwardly at the hinge line between said hinge member and said flap member permitting said bottom closure to be folded flat with the remainder of said carton for storage, and whereby when said carton is erected and said bottom closure is placed in planar position said overhang abuts the upper surface of said supporting flap member, thereby restraining said flap assembly from bending outwardly of said carton, and providing positive support for said polygonal flap.
 3. A carton according to claim 1, which is hexagonal.
 4. A carton according to claim 1, wherein said tabs have arcuate ends.
 5. A carton according to claim 1, wherein said tray is provided with vertically extending flaps frictionally engaging the side panels of said carton.
 6. A carton according to claim 1, wherein said top closure comprises a plurality of closure flaps hingedly connected to the ends of said side panels and interconnected laterally to form a closed loop, each of said closure flaps comprising a flap member and a triangular web hingedly connected thereto, said flap members and said webs each having an edge perpendicular to the hinge line connecting said flap members and said side panels and another edge oblique thereto, the oblique edges of said flap members and said webs being hingedly connected together, and the perpendicular edges of said flap members and triangular webs being connected to the perpendicular edges of webs and flap members, respectively, of adjacent closure flaps, the oblique edges of said flap members passing through the center of said closure when said flap members are in closed condition, said flap members terminating in an arcuate tab extending beyond the center of said closure.
 7. A carton according to claim 6, wherein said bottom closure comprises: a. a polygonal bottom panel being connected at one edge to the end of one of said side panels and having substantially the same dimensions and shape as the cross-section of said carton, and b. two supporting flap assemblies disposed one on each side of and below said polygonal bottom panel, each of said assemblies comprising:
 8. A carton according to claim 1, wherein a pair of apertures are provided in the side panels, a handle the ends of which pass through said apertures, and means anchoring the ends of said handle within said carton. 